FI RST CLASS

Permit No . 25

BUSINESS REPLY MAIL

NO POSTAGE STAMP NECESSARY IF MAILED IN THE UNITED STATES
McKees Rocks, Pe.

Postage will be paid by

Boiler Tube Q)mpany of America

BOX 151

McKEES ROCKS, PA. 15136

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 FAST - ACCURA TE - COMPLETE

BOILER TUBE SERVICE FOR BOILER TUBES?

WHERE ELSE?

Replacement Tubes - Bent or Straight

BOILER TUBE COMPANY

For ANY Bailor

OF AMERICA

OFFICES and PLANTS

The co mpany nam e says it best.

McKees Rocks, Pa. 15136
Boiler Tube Co mpany of America
41 2/771-1320

Lyman, South Carolina 29365

803/439-4488
1. The largest stocks of boil er tu bes
Or Call Toll Free 8 00-845-3052
KEE P THIS BOOKLET HANDY
It was prepared for you , the Bo iler En­
gineer. It provides useful and up to date infor­
mation on the care and preservation of boiler
t ubes and on the importance of intelligent
attention to boiler tube problems. Useful
tables, charts and memoranda are at your
.fingertips so long as this booklet is kept
within reach.
All tubing manufactured in the United
States. Boiler Tube Company of America does
not purchase or stock any foreign tubing.
has:
in the world.
2. Hot and cold bending facilities
with a full range of too ling.
3. A code weld assembl y plant w it h
multiple stamp approva l and com ·
plete facilities to hydro t est, heat
treat and ultrasonic t est after
assemb ly.
4. A file of over 20,000 drawings of
tube details and tube arrange­
ments for nearly every type of
boiler ever built. Your boil er prob­
ably matches one already in our
fi les.
5. 60 years in the business. 60 years
devoted exclusively to supplying
replacement boiler tu bes and tube
arrangements to keep existing
units operating with a minimum
of interruption .

Additional copies upon request, write ­

BOILER T UBE COMPANY OF AMERICA

McKEES ROCKS, PENNSYLVANIA 15136

Boiler Tube Q)mpany
LYMAN, SOUTH CAROLINA 29365

of America
 CONTENTS
PAG E
Compa ny Message .. . . . . . . .. . . . . . .. .4

Typi cal Boiler T ube

Company Capa bilities .. . . . . . . . ... 6-13

Replacing of Tubes ... . . . .. . . _ . . . . . 14

Furni sh and Install. . ... .. . . .. . . .. . . 15

Cost of Possessio n (I nventory) .... . ... . 16

Free Su rve y ... . . . . . . . . . .... . . . . . '7

Re vamp in g O ld Boi le rs . . .. . .. . . . . .. . 17

Specia l Service for Electric Utilities . . . . . . '8

Boiler Type Listing . .. .. . . . . . . . ... . 20

Bend ing Dat a . . . . . . . . . . . . . . . . .... 21

Conden sers and Heat

Exchange rs Rebu ilt ... . .. .. .. .... . 22

Code Assembly - Where

Know·H ow Co unts . . . . . . . . . . ... ... 22

The Im portan ce of

American Made Boiler Tubes .. ... .... 24

Energy Ma nage men t . . .. . .. . . .. .. . . . 26

Ca uses of Tube Fail ures ... . .. . . . . . . . 28

Prevention of Tu be Failures.. . ... . ... . 29

Boiler Tube Specificat ions. . . . . . . . .... 38

Tables:

Deci mal Equivalents . . . . . . . . . . . .. . . 39

Boiler Tube St ock Item Guide .. . . . .40-41

Pipe Weights & Dime nsi o ns . . . . . . . . .. 42

Wo rki ng Pressure Chart . ... .. . . . . . . . 43

2 3
THE BOILER TUBE
COMPANY STORY
T here are many large bo iler manu fact urers in
the United Stat es who design and build the
boilers that produce the electri al and steam
power that gives Am eri ca t he world's hig hest
sta ndard of living.
T here is just o ne company, however, t hat
was fou nded to prov ide the replacement t ubes
and tube elements needed to keep all t hese
boilers on line , and all t his power flowing ­
BOILE R T UBE COMPANY O F AMERICA.
Since 1918, t his has been the one purpose
of our business. We are excl usively a bo il er
tu be house. We carry the largest stocks of
boiler t ubes in the world and ou r shops can
fabricat e and code assemble any of the great
multitu de of tubing and tu be arrange ments
needed to provide a prompt and accu rate
replacement service.
World's Fastest
Boiler Tube Service
Perhaps no ot her word in the enti re business
d ict ionary has been so abused and misint er·
pret ed as the word "Service." Individuals and
concerns are cont in uall y blarin g forth with
offers to rend er "servi ce" in one for m or
: bending machines of varying capacity and has
another without hav ing an adeq uate apprecia·
t ion of just what t he word signi fies and with·
out having the personal interest in its fu lfill ·
ment the word makes necessary .
Years ago t his Co mpany ado pted t he
p hra se of " World's Fastest Boil er Tube
Servjce" with the firm int ent ion of making
t hat phrase ring tr ue at every test. We have
been and are fulfi ll ing t his Serv ice. Hardl y a
day passes but what we are ca lled upon t o
render superlatively fast boiler tube service.
4 5
We recognize our responsibility and we meet
it. We are mindful of the fact that an order for
immediate shipment does not mean next
month or three months - it means NOW. It
means perfect workmanship, as well. And so
we pledge ourselves to cont inue to render a
genuine boiler tube service, regardless of the
size of the o rder.
We welcome an opportunity t o serve you
as we are now serving customers in all of the
50 states, Canada, Mex ico, Caribbean, South
and Central America, and the Phil ippines.
Facilities
Boiler Tube Company of America has head·
quarters in Mc Kees Rocks, Pa. The origi nal
plant site at McKees Rocks is hemmed in by
surrounding industry where no suitable prop­
erty for expansion is available .
To cure t his proble m, the company, in
1971, acquired 22 acres of land in Ly man,
S.C. and erected a modern plant and off ice
building t o accommodate the growi ng req uire­
ments of t he busi ness. Lyman today has over
50,000 square feet of plant space and now
produces more than 60% of the company's
business volume. All code assembled tube
arrangement s fo r replacement superheater and
reheater sections are assembled in the Lyman
pl a nt . The company has nine hydra ulic
complete facilities for criti cal hot be nding,
swaging, heat treating, shot blasti ng, etc. Our
weld shops are equipped to produce a wide
variety of membrane tubing, incl uding large
straight or bent panel wall sectio ns.
When you locate all this bendi ng and code
fabr icating capacity under t he same roof, wi t h
the largest stocks of boiler t ubes available an y·
where in t he world , yo u create a boiler tube
replacement service that is unmatched.
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REPLACING OF TUBES FURNISH
AND INSTALL
The judgment of t he Boi ler Engineer, with
respect to t ube replacement, is an important Many plants prefer to have outside con­
factor in whet her bo iler life and efficiency is tracto rs do the work when large retubi ngs are
to be preserved at low cost. involved. Boiler Tube Company wi ll provide
Labor costs to replace a row of t ubes are competitive bids which will Incl ude all labor
far higher when the row is replaced piecemeal, and materi als for tear o ut and new installa­
a few at a time, t han if they were all cut out tion. Fie ld work of t his kind is handl ed
and re placed at once. Tu be costs are also th ro ugh ou r own fi eld division , whi ch
higher because the price savings in the higher operates out of our Lyman , S.C. plant. For
we ight brackets are not realized. Further, the jobs that are t oo remote fro m our Lyman
boiler must be pu lled off the line more fre ­ branch, we wi ll arrange to have bids submitted
q ue ntly with piecemeal tu be re placement. t hrough rep utable associ ated bo iler cont ract­
ing and engineeri ng firms.
F inall y, with a contin ui ng mix of doubtful
tubes in every part of your boi ler you risk th e
expe nse of being requi red t o do a complete
retu bing with the resulti ng waste of the many
good replacement tu bes yo u have already
installed.
Conditions of heat and circul ati on vary in
different parts o f a boiler. By row, conditions
are usuall y pretty much the same. Tube
t ro ubl e should be analyzed from th e stand ­
point of the boiler as a whole . Tube replace­
ment, if do ne with a planned Inte lli gence, can
pro vide many added years of trouble-free
effi ciency at a substantial savi ngs in cost .
A boiler is an expe nsive and vital piece of
equi pment. The boi ler tu bes are its blood
vessels. Neglect of water problems, and hap­
hazard tube replacements, wiII consign you r Lavout and Template Room
boiler to a costly life and an early death.

Bent Tubes Ready For Shipment

Part of Tube Storage Area

14 15
COST OF
FREE SURVEY
POSSESSION (inventory)
Inventories o f bent boiler t ube spares are
need Iess and extravagant. It is wasteful
enough t o tie up space and mo ney for in­
ventory tha t w ill ult imately be used, but to
spend money for spares that ma y never be
used is just not good sense.
We have seen plants w ith piles of bent tube
stocks which are nothing more than scrap.
Rows are intermixed and iden tifyi ng marks
are ob literated . In an emergency no one
knows which tubes t o use. Even when spare
tu be stocks are kept orderly and useab le they
represent waste because yo u are spend ing
money today for somethi ng you may need in
the undetermi ned future; or, may act ually
neve r need . T his is a foolish cost practice that
you would never t olerate in other materia l
buying.
The theory that you must insu re against
tu be fail ures is va lid only when replacem ents
are we eks or months away, as is often t he case
with t he boiler manufactu rer. Boiler Tube
Company of A merica elimi nates this need for
costly spare tube stocki ng. By assuring re­
placements in your plant w ithin a few days of
breakdown your new tubes are on ha nd by
the t ime the boiler cools and the defective
tubes are removed. You bu y only what yo u
need and on ly when you need it. In an emer­
gency we will start bending your needs im­
mediat ely and wi ll ship replacements t he sam e
or the following day .
16
We can backstop your bent tube replacement
stocks as soon as we have your comp lete
boiler data record in our files. A brief discus­
sion with your boiler engi neer and some
e x amination o f prints may be necessary
before we can com plete this file. We wil l con­
duct this preliminary survey without charge at
your invitation.
To obtain t his serv ice ch eck the block
marked "Boiler Survey" on the business reply
card in this booklet and drop it in the mai I.
REVAMPING OLD BOILERS
An old boi ler, retubed and reva mped, ma y
tu rn out t o be a better bo iler than a new one ,
an d at a lot less money.
Through the insta llat ion of waterwalls
many exist ing boilers can be stepped -up
sharply in capacity and efficien cy. In many
cases, it is possible to increase the capacity of
ex isting boil ers where their limitati on is due
to sl agging or burning of the refracto ri es.
Further, it is commonly foun d necessary,
In cases where the method of firing is changed
in an existi ng boiler, to alt er the ex isting
waterw " equipment t o fit the new firing
equipment. This requ ires special engineering
and often requires complicated bent tubes.
These waterwalls are always tied into boi ler
circulation so that they increase the steam ing
capacity of the boiler un its.
Boiler T ube Company wo rks in close asso­
ciatio n wi t h leading design engi neers in fa bri­
cating these complicated waterwall arrange­
ments. Specialists in this type of work will
undertake the contract fo r the brickwork
installation, and if desired, the firi ng equip­
ment and other related bo iler items in co nnec­
t ion with the boiler revamping.
17
SPECIAL SERVICE FOR
ELECTRIC UTI LITI ES
Bo iler Tube Company can almost always offer
replace me nt service on superheater, econo­
mizer and reheater sections at a favor able
price an d with shorter deli very t ime than the
original boiler manufact urer _ In addition, the
company offers a su pply so urce for electric
utility enginee rs who want to make changes to
cure defects in exist ing uni ts .
To day 's util ity co mpa ny en gineers, who
operate and main t ai n boile rs , are often a jum p
or t wo ahead of the boiler man ufactu rer
engineers who design and build the m. Some­
t imes , t o c ure a co ntinuing defect, a power
plant en gin eer may want to eliminate a tigh t
radius bend , o r institute a ch ange in wall
thickness, o r try a higher chrome alloy in hot
sectio ns. Boiler Tube Co m pa ny will fabr icate
these changes q uick ly an d to yo ur specifica­
tions.
Because of higher co nstructio n labo r cost s,
pollut io n control consideration an d ot her
regulat ions , t he cost of b uil ding new genera­
t ing capacit y conti n ues to escalate in leaps
Ail Ben t Tubes are Fitted on Full Size Tube
an d bounds an d is al most go ing out of sight . Layout
The way to low cost kilo wat ts can o ften be
foun d in reh abi litatin g ol der units back to
their origina l generating ca pacity . Boi ler Tu be
Co mpan y is ready to wo rk with ut il ity com­
pany engineers to prov ide boi ler t ubin g, tu be
arran gements or ele ments needed to acco m­
plish th is.
A f lexible a p proach to problems, per mit­
ting you to du plicate o ri gi na ls, or ma ke design
o r ma teria l changes in existi ng elements, pro­
vides a useful and cost savi ng service not al­
ways available fro m the original manufact urer.
Boi ler T ube Co mpany ser vice engi neers wi II
work with you on these specia l proble ms . Let
Hot Bent Tangent Tube
us show you what we can do.

16 19
 BENDING DATA
BENT TUBES
All bent tube are fitted to ful l si ze, shrink ·free
templates and are carefull y inspected before
The followi ng are among the best known
shipment. Bends are held smooth and free of
types of Bent Tube Boilers. We are prepared
injurious din ges, folds or crimps. Ro undness
to furnish replacement tubes promptly. Our
in t he be nd is held t o tolerances prescribed in
files contain tube details and engineering data
the trade. Wall thin ning, in t he back of t he
for all types of boilers. This file contains not
bend, becomes extreme when ti ght radius
o nly detailed information on most types of
bends are involved. Boiler Tube Company
boilers currently in manufacture, but nearly
t akes particular care to min imi ze such wall
all obsolete types as well. For man y boilers,
thinning t hrough the use of so phisticated
now out of manufacture, there is no informa­
tooling. If, in spite of t his , wall t hinning oc­
tion ava ilab le anywhere but in the flies of
curs beyond acceptable levels, we will hot
Bo iler Tube Company of America. Inquiries
bend close radius bends to assu re reasona ble
should specify Letter or Number Class of
wall thickness . Our inspectors wi ll make ultra­
Bo iler and Tube Row Number.
Badenhausen Keeler
B.&W . Kidwell
Bigelow Ladd
Connelly Maxim
Casey Hedges Ril ey
Cleaver-Brooks Ross
Combustion Rust
Collins Springfield
Edgemoo r Stirling
Erie City Titusville
Heine Union Iron Works
Foster Wheeler Vogt
G. E. Waste Heat Wickes
We carry a large and complete stock of
tu b ing in regular and heavy gauges and can
make prompt shipment.

TITUSVI LLE BOI LERS

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Tube Lavour Table

Boiler Tube Compan y of America has ac·
quired all rights to Titusville water tube
boilers in connection with tube replacement .
We have a co mplete drawing file with all
bending details and can f urnish replace ment
tu bes promptly for your Titusville boiler.
S nic readi ngs of ti ght radi us bends to assure
to p quality of bend.
More than 20,000 drawin gs of boi ler ar·
ra ngements, t ube details, etc. are cataloged
and cross·fi led in o ur enginee rin g department.
These dra wings are representat ive of nearly
every type and manufa ure of boiler built in
this cent ury . Your bOiler, or one almost
identical to it, is probably somewhere in this
file. When we have enough information to

20
21
properly identify and cross·match your partic· pro perties are restored to tu bing, the units are
ular boil er, we can p ro vide re placement tubes less like ly to give the long service life expected
pro mptly, accurat e ly and at a substantial and could result in prematu re t u be failur es.
savings in co st. These metallurgical and physical changes,
and the decisions needed to correct t hem, are
CONDENSERS AND not usually co vered by the requirements of
HEAT EXCHANGERS REBUILT t he boiler code . If protective heat treating
procedures, wall thickness and wa ll thickness
Tu be bundle failures mean critica l delays in all owance st andards, are not specified by the
pro ductio n . Quality repairs, or replacements, custome r in advance, t he n the supplier must
done quickly , are often impossible. At o ur be t rusted t o build these protect io ns into the
Ly man plant we can rebuild heat e xcha ngers, fabricating procedure. Ma ny code approved
condensers and t ube bundl es quic kly. Most assemblies will crack or fail in service because
co mmon size conde nser tu bing is carried in t hese details have been overlooked. Boiler
stoc k. Necessary reb uild in g can be don e often Tube Company makes careful review of such
t imes in days , rather tha n weeks or months . needs to make the needed recommenda tions
All bundles , upon co m pletion , are t ested t o t o customers. Code asse mbly an d Code papers
o ne and one-hal f ti mes the maximu m working are ooe source of protection but Code, by it ­
pressure. self, is not enough .
REMEM BER .. . the s uppli er must be de­
CODE ASSEMBLY ­ pe ndable and must have the abili t y to make
WH ERE KNOW-HOW COUNTS t he required de cisions to produce top quality
assembled t ubing ele men ts.
When tu bi ng ele ments for superheaters, re­
hea t ers and economizers are Code assembled,
t he rigid specifications covering t he t ubin g
is onl y half the story _ T he specificatio n
covering t he Code assembl y itself is t he other
half.
It is not enough just to say tha t elements
must be put t o gethe r and tested in accordance
with Code procedures . In the very process of
code fab ri cation, t he metallu rgica l and
mecha nica l properties of t he t ubing may be
changed so t hat the tubing may lose proper­
t ies essentia l to long li fe at elevated tempera­
tures and press ures. Bending can work harde n
the tubes and set up stresses _ T ight radius
bending may reduce wall thickness at the back
of the bend below design requirements_ TUbe­
t o-tube welding, as well as weldi ng of spacers,
ha ngers and other attachments t o tube sur­
faces, may set up stress forces and, in some
cases, reduce the resistance of the materia l t o
corrosive attack. Thus , many specified tubing
properties may be removed . Un less t hese lost Roar Pass Weld for Code Jointure

22 23
ENERGY MANAGEMENT
Rem em ber w hen good quality fuel was readily
\
,
..
availa bl e and when we neve r heard o f scrub­
bers, particulate em issions, t he rmal pol luti on ,
and a hundred other enviro nmen tal te rms. In
those days we didn 't bot her t o manage ene r­
gy , we just used it. Today is different. Energy
management means managi ng the cost of
energy . We have to manage energy t oday be­
cause it costs so much mo re . We simply have
to utilize the BTU's more effici entl y.
Ma na gement means decisions - energy man­
age ment means energy decisions. Energy
decisi o ns involve boiler operati o ns, design
changes, added capacity , rehabilitatio ns, etc.
Outside ass istance to defi ne and solve boil er
proble ms often makes these decisions easier to
reach. Eng ineerin g and consulting se rvices of
this ki nd are avai lable f rom Boiler Tube
Company o f America.
Hot Bending on Hydraulic Press

Tube Cu t-off Mach ine Assemblies Readv f or Fit-up in Weld Shop

26 27
 PR EVENTION OF TU BE FAILU RE S
CAUSES OF TUBE FAILURES Generating Tubes
Boi ler generating t ubes fai l for one of three
1. HA RD SCALE reasons. They have been overheated ; they
Treatment have been attacked chemical ly on either the
Lime and Soda Ash or Zeolite ahead of water or fire side; o r t hey have been thinned
down fr om the fire side. Overheati ng may be
boi ler - Phosphate internally .
caused by deposits on the water side wh ich
2. SLUDGE preve nt adequate cool ing of the tu be meta l, or
by unusually hot zones in the furnace. The
Treatment
pro ble m of chemi ca l attack is in some cases
Co n c e n trates of Phosphate Silica and related t o overheati ng, as high temperat ures
Alkal i. Wash outs and blow downs. Poly­ great I y speed up certai n chem ical react ions
meric Conditioners. Chelating Agent s. High involving iron. Most chemical attack ca n be
sludge ma y be tolerated if. dispersive prevented , however, b y proper boile r water
materials such as lign in derivatives are used. treatment.
3. CHEMICAL ATTACK External thinn ing may be ca used by the
improper placement of soot bl owers and, in
Attack by Treatment
rare cases, by abrasi ve part icles in the fuel.
1. Steam - Circulation in­
crease- Baffl e Scale
changes
Around the boiler ho use we fr equentl y hear
2. Concentrated - Amine t reat ment the word " scale" used to describe an y ki nd of
Boiler Water to reduce deposits boi ler de posit. Several decades ago a d epos it
of corrosion found in a boiler t ube was undoubtedl y scale,
products but since t he advent of internal chemical con­
3. Caust ic - Sod iu m Nitrate dition ing nearl y all boiler de posits have been
sl udge. What is the difference between scale
4. Acid - Frequent
and sludge? Simply this: Scale is preCipita ted
alkali ni ty checks
from solution where you fi nd it, sim il ar to the
-Fuel condit ioners
bu il dup whi ch forms in a t ea kettle ; sl udge is
5. Stress corrosion and - Baffle re pair, etc.
suspended material in the bo il er water, which
Corrosion fatigue
under unfavo rable conditions st icks to boiler
6. Oxygen - De aerators­ surfaces.
Sodium Sulfite
Today we shoul d neve r see scal e of the
7. Damage in - See Page 35
ty pe resulti ng from hardness in t he feed water
stand by
because of the practically unive rsal acce ptance
of internal t reatme nt wit h phosphate , wh ich
precipitates t he hard ness el ement , ca lciu m, as
All t ubin g manufact ured in the Uni ted soft sludge rather tha n hard sca le. It is esse n­
Stat es . Boiler Tube Compan y of America does t ial , particular ly in mode rn boilers whe re heat
not pu rchase or stock an y foreign t ubing. transfer rates are high, that scal e format ion be
prevented, not just because the insu lating

28
29
effect may decrease fuel efficiency, but be­
cause sca le prevents the boil er water fro m
coo li ng t he t ubes in which it has form ed,
allowi ng them to overheat and ulti mately
ruptu re_
All boiler makeup contains some ca lcium,
t hough modern treati ng equipment permits its
red uct ion to a concentration of one part or
less in a millio n . Th is may appear to be a n
ins ign ifica nt amount of material, but in a large
boi ler not having the benefit of a high per­
centage o f condensate returns, th is may repre­
sent t he introduct ion ·of ma ny pounds per day
of hard ness, which, if not properly t reated ,
could cause tubes t o fa il in a relati vely short
period of t ime_ To date t he best method of
combating calcium sca le is pretreatme nt with
lime and soda ash or wi t h zeolite for removal
of most of the hard ness ahead of the boiler,
followed by internal treat ment with phos­
phate, phosphate plus a sludge conditio ner or
t reatmen t with a chelating agent_
Not all scales c{)ntain calcium. The higher
pressures and heat t ransfer rates made possible
by the e limination of ca lci u m sca le have given
rise to anot her problem, namely, deposition
of relatively soluble compounds in heavi ly
worked port ions of the boi ler. Steam is
generated right at the tube surface, whe re the
tempe rature is t he greatest. If t here is not suf­
f icient rinsing of t his surface, boi ler wate r
solids will be deposited in the form of scale.
Und er extreme conditions even such highly
solub le materials as common salt may precipi­
tate _ Under less severe conditions, ri nsing may
be sufficient t o prevent such depos its from
formi ng, but the t ransfer of heat f ro m meta l
to water may be enough to produce o n t he
tube surface a fi lm of boiler water so co ncen ­
trated that t he solubi lity of certa in com­
pou nds of iro n, aluminum sodium, a nd silicon
is exceeded.
30
Where scale is fo rmed because of insuff i­
cient ri nsing or a too high ly con centrated film
of water, deposition can be mi ni mized by (1)
in creasing liq uid velocity to obtain better rins­
ing and d issipation of the concentrating film ,
(2) decreasing or redistribut ing heat in put so
t hat lower concent rations w ill prevail in the
water film and less steam wi ll be generated in
t he affected rea, and (3) mod ifying boiler
wate r compositio n to reduce the concentra­
tion o f scale forming elements .
N o te How Hard Scale Forms on Insu lati ng Wall
Inside Tube
Sludge
With the passage of water treatment from t he
realm of art to that of science, we have wit­
nessed the successful el imina tio n of calcium
scale in th e boilers . T his leaves the seri ous
problem of sl udge fa ci ng the water chem ist
and t he boil er house operator. As long as
slud ge ca n be ma inta ined in a sus pended con­
di tion, its presence in the boil er wate r may be
t ol erated, but when it is sti cky and becomes
ba ked onto genera t ing surfaces it , too, acts as
an insulato r. In some in stances, t hin laye rs of
adherent sludge wil l slough off t he tu be or
dru m surfaces and accum ulate in bends near
t he lower ends of tu bes, reduci ng circulati on
and perm itting overheat ing .
31
 The sticky nat ure of slud ge is best com ­
bated by t he mai nt enance of proper phos­
phate, si lica, and alka li concentrations in t he
boiler w ater _The amount of sludge circulating
with the boiler wate r is he ld to a m inimum by
effective pretreatme nt fo r removal of hardness
fro m the feed wate r. Whe re raw water is used
or w here hardn ess remov al is poor, high blow­
down rates are requ ired to limit sludge con­
centra ti ons in the bo il er. Frequently high
sl udge concentrations may be t ol erat ed when
certain sludge condit ion in g materials are fed
to the boi ler. Lignin der ivatives have been
used for a gr at number of years and more
recently pol ymeric sludge cond itioners have
successfully de monstrated thei r effect iveness
in minimizin g bo iler de positi on_
In the past ten to fi ftee n years, chelat ing
agents such as EDT A (ethylenediaminetetra­
acetic acid ) or NTA (nitri lot riacetic acid ) have
become an importa nt t ool in internal
t reatment.
Chelating agents ha ve the ability to tic up
hard ness in a soluble form and avoid the for­
mat io n of suspended soljds_ Cost is an impor­
t ant factor and chelat ing agents are only
practical when feedwater hardness Is low.
Control and methods of feed ing are criti cal
and if not pro perly ha ndled can result in
serious corrosion_
Chemical Attack
The on ly substance in boi ler wate r that
actually reacts with the iro n in the bo iler st ee l
is t he water itself. However , oxygen , ca ust ic,
and other boi ler water solids may affe ct the
rate of react ion or cause it to occur in
local ized areas_ Hydrogen , which is produced
in t he react io n between water and iron can
embrittle the me tal by react ing with t he car­
bon in t he steel to prod uce met hane gas.
32
Stea m will attack t he tube meta l in regions
of local ized over heating where ri nsi ng is insuf­
ficient and the surface beco mes bla nketed
with steam. Increased water circulation or
mod if icat ion of furnace baff ling t o decrease
heat input wi ll usua lly re med y t his condit ion.
Caustic ma y cause damage in t wo differen t
ways. Caust ic in the concentra ti ng film pre­
vio usly mentioned , may str ip off the pro­
tective Iro n oxide coa ti ng, which is nor mal ly
present on tube surfaces, per mi tting the
exposed iron to react with wate r. Not o nly is
metal remo ved by this process, but the re­
mai ning metal in the area may be embritt led
by the hydrogen give n off in t he rea ctio n.
In plants that retu rn a large perce ntage of
co ndensate to t he boi le rs, caustic a nd ot her
boiler water solids, such as t risod ium phos­
phate, may cause chemical attack. Such attack
o ccurs beneath deposits of corrosio n products
having their so urce in t he co nde nsate syste m.
These corrosion product s, wh ich are no rmally
the oxides of iron and copper, are hea vy and
tend to settle out on heat t ra nsfer surfaces,
pa rt icularly at the burner level in waterwall
t ubes and just beyond sharp bends toward the
hor izo ntal , a confi guration fr equent ly found
in superheater screen t ubes. Beca use these
d e posits are porous, they prov ide a t ra p in
whi ch boi ler wate r solids can co ncentrate
while int erfering wit h the normal ri nsi ng of
t he t ube surfa ce. Obviously, damage to the
tu bes beneath these oxide depos its can be
reduced by keeping the a mounts of iron a nd
copper returned to the boi ler with the con­
densate at very low levels. Today this is
accomplished by t he additio n of neut ra lizing
ami nes to raise the pH of t he co ndensate or
by fi lming amines that provide a no n-wettable
barr ier between the condensate an d t he meta l.
Caustic may also embrittle metal in areas
adjacent to minute leaks, such as are likely to
33
exist arou nd tube ends where rolli ng of t he
tube int o t he d rum has not been carefu lly per­
fo rmed . Boi ler water passing thro ugh t he
o pening flashes in t he red uced pressure of t he
at mosphere and leaves some of its solids,
including caustic, in the openi ng. A sufficient
a mou nt of causti c, th us depos ited, causes t he
metal of both drum and tube to become
b r itt Ie. Ca u stic emb ritt lement has been
successfull y prevent ed, even when leaks have
occured, by the mai nte na nce of a suitable
rat io of caustic to other substances, such as
sodium nitrate, in t he boile r water.
Operation under acidic conditions is a par·
t icularly destr uctive practice, although dam ­
age fr o m th is source is rare nowadays_ Acid
water removes t he ox ide coati ng from the
meta l, just as high ca usti c concentrations do,
and allows the boiler water to react with the
iron_ It is now accepted practice to insure a
suita ble level of alkali nity by frequent check­
ing of boiler water samples_
An un usua l type of attack is corrosion
fatigue , caused by t he reaction of water with
tu be meta l in wh ich stresses fl uctuate. Stresses
in the t ubes may be set up by non uniform
fir ing or by loose bricks which have beco me
lodged in such a way as to prevent free move­
ment of the boiler metal as it expa nds on
heati ng. Fau lty baffl in g shoul d alwa ys be re­
paired to prevent loca l overheati ng and to in ­
sure t he uniform f low of hot gases t hrough
the f urnace .
Under some circ umstances oxygen in the
feedwater ma y cause scattered pitti ng in the
boiler _ T he most effective measure tor pre­
venting t his type of attack is t he reduct ion of
oxygen to a very low leve l by passage of the
feedwater through a good deaerating hea ter .
However , some boilers are susceptible to cor­
rosion even at e xtremely low levels of oxygen,
34
in which case protection is obtained by the
a ddition of oxygen scavengi ng chemica ls,
notabl y sodi um sulfite, to t he bo iler water .
Standby
The damage done by oxy gen to no noperatin g
boi lers canno t be overem phasi zed . Boi ler
t ubes ma y de velo p large pi ts d uring ei t he r wet
or d ry standby if pro per precauti ons are not
observed . A boi ler in we t stand by sho uld be
checked freq uent ly. to see t hat the proper
leve ls of alka li and sodium sulfi te are main­
tained in the bo iler water . Trays of q uicklime
shou ld be placed in a boi ler in dr y sta ndby t o
prevent damage by oxygen -cont ai ning con­
densate or eno ugh hea t sho uld be ap plied to
keep t he meta l tempe rature abo ve the dew
point .
Failures from the Fire Side
As has been indicated, ma ny of t he diff icult ies
arising on the water side of t he t ube are the
result of overheating. This co nd itio n may be
the result of difficulties on the fire side, such
as defective baftling or poor furnace design. In
the case of forced dratt chain grat es, where
the arch is not properly designed and in the
case of underfeed stokers, theril is often a
blow-pipe effect near the lower ends of t he
tube, due to the constriction of gases in th is
regio n, with t he result that extreme tempera­
tures are obtai ned .
Corrosion on the fi re side of tubes is some­
t imes a problem in the boiler itself and in par­
ticular in economizer sections. Bituminous
coals and fuel oils quite often contain sign ifi ­
ca nt amounts of sulfur which decomposes to
35
 .,
acid gases on burn ing. Where tem peratures be­
come suffi ciently low to allow moisture con­
taining these gases to condense on the out side
of t he tu bes, su lfuric acid is prod uced and this
ca n be extremely aggressive to t he tube metal.
Fuel condi tione rs are available that can be
appl ied to combat t his type of tube corrosion.
In addit ion to the low temperature corrosion
resulting from sulfur, some fuel o ils contain
vanadium that can corrode boil er tubes in the
high temperatur area of the boile r. Vanadium
corrosion can also be minimized with fu el
additives.
T ubes may also fail from the fire sid e b y
the abrasive action of fl y ash and dirt parti cles
in the fuel. In some steel mi lis, where blast
furnace gas is uscd as a fuel, t his is a f req uent
cause of failure. In some Instances, it has
proved econom ical to wash the gas prior to
firi ng.
A freque nt cause of tube failures is the cut­
ti ng action of steam from improperly placed
soot blowers.
Superheater Tubes
Superheater tubes rarely fail because of corro­
si on, unless it has occurred duri ng periods of
standby. Fa ilures of these t ubes are almost
always attr ibuted to overheating, which may
be caused by the insulati ng effect of deposits
carried over from the boiler water, or by
starvatio n.
Deposits ha ving t he ir origin in the boiler
water are carrie d over because of foaming in
the st eam dr u m, resulting from excessive con ­
centrations of disso lved so lids o r alkali or t he
presence of oil o r other organic sub tances.
Foaming caused by high solids a nd alka li nity
may be minimized by increasing the boi ler
blowdown or by the addition of an antifoa m
material to the boiler water . The elimination
of organi c con taminan ts may require speCia l
pretreating equi pment or t he insertion of an
36
oi l se parator in the feedwater line. It should
be emphasized here that pure hyd rocarbon
o ils do not ca use carryover, but that additives
in them frequently do .
Carryover in the form of slugs of water is
another cause of superheater deposition, and
this may be remedied by lowering the water
level or by obtaining better water level con­
trol. However, heavily swi nging loads in excess
of those for which the boiler was designed
may also contribute to this condition.
Starvation of su perheater tubes may result
from poor startup practice or by operating the
boiler at undesirably low rating. If, during
startup, the furnace temperature is brought up
too rapidly before full boiler pressure is at­
tained, there will be insufficient steam to cool
the tu bes. In boilers with a radiant type super­
heater, this same effect may be noted at low
loads.
The foregoing discussion was prepared by
the Comulting Staff of the Water Management
Division, Calgon Corporation, Pittsburgh,
Pennsylvania.
CAUTION - Water treatment is a highly tech­
nical science requiring careful analysis of
water content, boiler design and operating
conditions before treatment can be recom­
mended. Chemica l peddlers, with their "cure
all" bag of mysterious chemicals can do far
more harm than good to vital boiler equip­
ment . There are many reputable firms
specializi ng in industrial water consultation
who will give expert counsel in these matters.
Don't take a chance - Consult an expert .
37
 .,
Advoca tes of seamless tubing prefer no
BOILER TUBE weld seam in the tube wall. T here is t ho ught
SPECI FICATIONS to be further protect ion in the heav ier nom i­
nal walls of seamless due to the method of
manufacture. Further, t he "piercing" process
Specifications for boiler t ubes, or "pressure" in making seamless tubes imparts a tough m ill
tu bes, gen eral ly appl y to t ub ing used in sea l to the tube su rface which appears to
boilers and heat exchangers where the tubing make it more resista nt to corrosion.
is used as a heat tra nsfer medium. Th is in­ Electricwe ld t ubes are fav ored because of
cludes tubes for the ge nerating and s uper· lower costs, more uniform wa ll and un iform
hea ter sections of boi lers as we ll as tubes fo r heat transfer. Welded t ubes, because they are
economi zers, co ndensers, fe edwate r and more unifo rm, are easier to ro ll and install.
waterwall sections.
The fo llow ing specificati ons are in genera l
Bo il er tu bes are made in both seaml ess a nd use for boiler tubes and cond enser t ubes.
electr ic res istance weld. T ubi ng made by
eit her process is rigid ly co ntro lled and tested GRADE SPECS.
both dur ing a nd aft er rolling to meet th e Lo w Carbon Seamless A-'92, A-179
exacting specificati on requireme nt s of a pres· Low Carbon Electricweld A·178, A-214,
sure t ube. The boiler · code appro ves e ithe r A-226
method of ma n ufactu re and ex presses no Med. Carbon Seamless A·210
preference. Med. Carbon Electricweld A-178 Grade C
Low Al loy (Corten or A423 (Seamless
The vast maj ority of boiler tubes in use are Republic 50) or Welde d)
made of low carbon steel which is suitab le fo r
Carbon Mol y Seamless A-209
use when continuous operating tempe rat u res Carbon Mol y Electricweld A·250
do not exceed 750 0 t o 800"F or, under ideal Al loy Seamless A·213 (T Seri es)
corrosion free condit ions up to 900"F. Whe n Stainless Seamless A-213 (TP Series)
t emperat u re ra nges are near the critical points Stai nless Electricweld A-249 (TP Series)
for low ca rbon the higher yield st rength of
medi um carbon o r ca rbon moly is so metimes
used to give added protection. Elev ated
DECIMAL EQUIVALENTS
te m peratures in high outpu t large power
boi lers frequen t ly require the use of alloy or 1164 .0156 17/64 .2656 33164 .5156 49164 .7656
stai nless t ubes. 1132 .0312 9 /32 .2812 17/32 .5312 25132 .7812
3164 .0468 19/64 .2969 35164 .6469 51164 .7969
So iler tubes, t o comply to specificat ions 1116 .0625 5/ 16 .3125 911 6 .5625 13116 .8125
a nd meet all owable wo rking pressure rat ings, 5164 .0781 2 1/64 .328 1 37 /64 .5781 53/64 .8281
are always expressed and sold as min imum 3/32 .0937 11 /3 2 .3437 19132 .5937 27/32 .8437
wall. 7/64 .1094 23/64 .3594 39/64 .6094 55/64 .8694
l iB .126 3/8 .375 518 .625 7/8 .875
Whether to use seamless or e lectricweld 9 /64 .1 406 25/64 .3906 41/64 .6406 57/64 .8906
boil er tubes is largely a matter of person I 5/32 .1562 13/32 .4062 21/32 .6562 29/32 .9062
11 /64 .1719 27/64 .4219 43164 .671 9 59/64 .9219
preferen ce. Electricweld bo iler t ubes are sel­
3/1 6 .1 875 7/ 16 .4375 11/ 16 .6875 15 / 16 .9375
do m made in t he alloy ranges but in the car­ 13/64 .2031 29/64 .4531 45/ 64 .1031 61/64 .9531
bon and st ai nless grades they are fully co m­ 7132 .2187 15/32 .4681 23/32 .7187 31 /32 .9687
parable to seam less by sta ndards of bo i ler 15/64 .2344 3 1/64 .4844 4 7/64 .7 344 63/64 .984 3
cod e require me nts and general acceptan ce. 1/4 .26 1/2 .5 3/ 4 .75 1 1.0

38 39
 BOILER TUBE STOCK ITEM GUIDE
SA-H8 - Electric-Resistance-Welded Car bon Steel
Boi ler T ubes
SA-1 79 - Sea mless COld -Dra wn Low Carbon Steel
Heat Exch anger and Condenser Tubes
SA-192 - Seamless Carbon Stee l Boiler T ubes f o r
High Pressu re Serv ice
SA-209 - Sea mle ss Carbon Moly Alloy Steel Boiler
& Super hea ter Tubes
SA -210 - Sea mless Mediu m Carbo n Stee l Boiler an d
Superh eater T ubes
SA-21 3 ­ Sea mless Chrome Alloy and Sta in less Steel
Bo iler, Superhea ter and H. E. Tubes
SA -21 4 ­ ERW Ca rbon Steel H. E. and Condenser
T ubes
SA -423 ­ ERW a nd Seamless "Corten" Pressure
Tubes
SB-11 1 ­ Co pper Alloy " dmiralty " Conde nser
Tubes

WALL
TUBING (I) CHECK MARK INDlC'.TES TUBE SPECIFICATIONS REGULARLV CARRIED
THICKNESS
0.0.
RANGE
INCHES SA-178 SA-179 SA-19i SA-209 SA-21D SA·213 SA-214 SA-423 SB·111
INCHES
1/2 ,049 ./ ./
5/8 .049 to .083 ./ ./ .;
3/4 .049 to .105 .; ./
7/8 .049 ./ ./
1 _083 to .134 .; .; ./ ./ .;
1-1 /4 .095 to ,260 ./ .; .; .;
1-1 /2 .095 to .438 ./ ./ ./ .; .;
1-5/8 .120 to .300 .; .; .; .;
1-3/4 .095 to .480 ./ .; ./ .; .;
1-7 /8 .135 to .438 ./ .; .; .; .;
2 .095 to .500 ./ .; .; ./ .; .;
2·1 /8 .165 to .500 ./ .; ./ .;
2-1/4 .105to.500 .; .; ./ .; .;
2-1/2 .105 to .500 .; .; .; ./ ./ ./
2-3 /4 .120to .360 ./ .; .;
3 .105 to .400 ./ ./ ./ ./
3-1/4 .120 to .300 ./ .; ./
3-1 /2 .120 to .300 .; ./
4 .134 to .220 ./ ./ .;
4-1/2 .120to;320 .; ./ ~
.;
5 .165 to .500 .; ./
5·1 /2 .165 ./
6 .180 ./

40 41
 MAXIMU M WORKING PRESSU RES FOR

WATER TU BE BOI L ERS

Maxi mum Allowable Working Pressures fo r Sea m·

less Stael a nd El ectric-Resista nce-Welded-Steel Tubes
or Nipples fo r Wate r T ube Boilers, where Expanded
into Drums or Headers, fo r Di fferen t Diameters and
Gauges of T u bes Co nfo rmi ng to the Requirements of
Specificat ions SA-83, SA-17 8 Grade A, SA-1 92 and
SA·226.
WE LDED AND SEAMLESS PIPE A pproved 1965
A.S. T.M. Specifications A53-30 !:! ~ fiQ ~~~ ~o~~~:?~
Weights and Dimensio ns ..;.
I I I I I I I I
to" ~ Q)~ ;: ~~~~~~ ~
o oo ~ oooooooo
... I I I I I I I f8 ~ ~ ~N~ ; g~~8
.-_ .... ... .... ,....,....N
I I c;
o
!! ~ ~~~~~ ~~a1~~~ I I I
I I I I I I M
...
M r-- COcn O..--Mq-U')I"COO
... ,.... ............ ,.....--N
00000000000
Dia me ters. Weigh t per !:! I I I I I l'\.IO r- N N " N " O " N I
I "- I I I
Inches Wall Foot , poun d :; Thrnad s COOlO P'"N"I:t LO"COO
Size,
Inches
I hlck-
n<S, J .p(;r
til ~~r- r- r- _ r-N

-
Ex ler' [ Inter Plai n Th ma<k
na l nal Inch Ends
and In ch !! :iig g~g~ ~R~ I I I I I
Cpt'gs. I I I I I I ..::roo m ......
N c.-,lOI'COO
til ~ ... r- ............. N
FULL ST AN DAR D WEIGHT o o o o c O Q OO
m ~ CQ cn",, ""' N <n" I I I I I I I
0.850 M I I I I I
1/ 2 0.840 0.622 0.109 0 .8 52 14 M~ Q) e ~ ~~~~
3/4 1.050 0.824 0.113 1.130 1.1 34 14
1 1 .315 1.049 0.133 1.678 1.684 11 . 1/ 2 ~:~ oo o ooo
~ !'.
1·1 /4
1·112
1.660
1.900
1.380
1.610
0.140
0.145
2.272
2 .71 7
2 .28 1
2.731
11 · 1/2
"·1/2 ",'
'?
N
I I I I
aJ~ ~ ~ ~ §E I I I I I I I I

2 2.375 2.067 0.154 3 .652 3.678 11 ·1/2 III 00 00 0 0 0 0

t;; !:!
2·112
3
2.875
3.500
2.469
3.068
0.203
0.216
5.793
7.57 5
5.819
7.616
8
8 ::;: ~
I I I I
~ ~!~~~ ~ ~ I I I I I I I I I

3-1/2 4.000 3.548 0.226 9.109 9.202 8 4:

4 4.500 4.026 0 .237 10.790 10.889 8 0 :<! go oo cc c
4-112 5.000 4.506 0 .24 7 12.538 12.642 8
w
0
~
N
I I I I
~ r;;s ~~~ ~ I I I I I I I I I I

5 5.563 5.047 0. 258 14 .6 17 14.810 8 C;; O OO O Q o o

6 6.62 5 6. 065 0.280 18 .974 19.185 8 ~
7 7.625 7. 023 0 .301 23.54 4 23.769 8 :=J
0
N I I I
:; ~~~~~ ~ I I I I I I I I I I I
8 8.625 8.071 0.277 4.6 96 25.000 8
8 8.625 7 .98 1 0 .322 28.554 28.809 8 w 0 000 00
!!
-
al
:;) ":' I I I ~ ~ ;;rn;!!~ I I I I I I I I I I I I
EX TRA STRO N G ~ ..... r- ..... N

1/2 0.840 0.546 0.147 1.087 - !:! g g~ g ~

--
-
3/4 1.050 0 .742 0.154 1.473 - I I V LO ,... te oo I I I I I I I I I I I I I I
0:-
1 1.315 0.957 0.179 2.171 -
1·1/4 1.660 1.278 0.191 2.996 - -
!! 0000 0 0
1·112 1.900 1.500 0.200 3.631 - - r
Lf)t.n'lllf~CIO
I MIn ,...,.... en I I I I I I I I I I I I I I I
2 2.375 1.939 0.218 5.022 -- -
2·112 2.875 2.323 0.276 7.66 1 - !!? OOOm
3
3- 1/2
4
4·1/2
3.500
4.000
4.500
5.000
2.900
3.364
3.826
4.290
0.300
0.318
0 .337
0.355
10.252
12.505
14.983
17.611
--
-
-
-
-
-
--
-- _N",
I ..::r c,o <D_ I

000
I ~~ :g I I
I

I
I

I
I

I
I

I
I

I
I

I
I

I
I

I
I

I
I

I
I

I
I

I
I

I
I

I
I

I
5 5.563 4.813 0.375 20.778 -
6 6 .625 5.761 0.4 32 28. 573 - -
7
8
7.625
8.625
6.625
7.625
0.500
0.500
38.048
43 .388
-
- -
- !!
0000
~rg~~ I I I I I I I I I I I I I I I I I
'"

1
1/2
3/4
0.840
1 .050
1.315
DOUBLE EXTRA STRONG
0.25 2
0.434
0.599
0.294
0.308
0.358
1.714
2.440
3.659
-- -
-
- ;;
-
.. .
!:::!
oo
a:10 0«>
mo I I I I I I I I I I I I I I I I I I

1. 1/4 1.660 0.896 0.382 5.214 - -

-
~
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1·112 1.900 1.100 0.400 6.408 -
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2 2.375 1 .503 0.4 36 9.029 - -
2· 1/2
., 2.875 1.77 1 0.552 13.965 - -
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3.500 2.300 0.600 18 .583 -. ~
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3-112
4
4.000
4.500
2.728
3.152
0.636
0.67 4
22.850
27.541 3: .!l -
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4-1/2
5
6
5.000
5.563
6.625
3.580
4.063
4.897
0.710
0.750
0.864
32.530
38.552
53.160
-
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7 7. 625 5.875 0.875 63.079 - NOT ES : These values have been calculated by the
8 8.625 6.875 0.875 72.424 - - fo rmu la in PG-27 . usi ng allowable stress values at a
te mperature of 700 0 F. Values above the solid hne
include an additional thickness of 0.04 in . to compen­
sate fo r thinning of tube-ends due to the exparlding
process .
 Regular review an d revision of our Boiler ni
Data File is t h e best w ay we kno w to give you 00 LD
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pro m pt re pl ace me nt t u be service when y ou «
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it, you will be establis h in g for your co m pa ny a
prompt and depe nd able sou rce fo r replacement
Bo iler Tubes. This infor m ation, in our fil es,
wi ll save you future time and dollars. ca

If you wou ld like a represe ntative to ca ll,

please check the appropriate block. .­
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All tubing ma nufactured in the United
States. Boil er Tube Co mpa n y of America do es
no t pu rchase or stoc k any forei gn tUbing.
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